EtherCAT Training

EtherCAT

1. General EtherCAT 2
o Features
o Sync Unit
o Frames
o Working Counter
o Topology
o Redundant System

2. EtherCAT Master 7
o Topology
o EtherCAT State
o State Machine
o Addressing
o FrameState
o DevState

3. EtherCAT Coupler 22
o CRC
o Port Status
o Working Counter

4. EtherCAT Terminal 29
o Profibus Master Terminal
o CANopen Master Terminal

5. TwinCAT PLC 35

6. EtherCAT Diagnosis 40
o Diagnosis with TwinCAT SystemManager
o Diagnosis with TwinCAT Topology View
o Diagnosis with TwinCAT PLC Library
o Troubleshooting
o Advanced Diagnosis with Network Monitor

7. HPN Part List 67

8. Notes 68
o Firmware Update

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1. General EtherCAT
EtherCAT Features
• no manual setup of node addresses
• no IP Address configuration
• no setup of Baud rates
• no restrictions in network topology
• no (practical) limitation of the maximum number of nodes (max. 65535 nodes/segment)

Main Features: TwinCAT and EtherCAT

• offline configuration in TwinCAT System Manager: select EtherCAT master and add the EtherCAT slaves (Terminals)
• online configuration in TwinCAT System Manager: scan network and all EtherCAT slaves in the topology will be listed
• TwinCAT assigns logical slave addresses automatically
• add new slaves without changing the logical slave addresses
• compare configured EtherCAT network with real existing EtherCAT network
• separation from process data and bus diagnosis (helpful to make modular control architectures)
• mapping between physical and logical process data has to be configured (same as in all other field busses)

Main Features TwinCAT V2.10

• TwinCAT and EtherCAT: easy configuration and diagnosis
• for simple and complex control applications
• default settings for most applications sufficient
• manual configuration for optimal tuned complex applications
• Sync Units for combined and synchronized process data
• any process data can be logically combined in one sync unit

Sync Unit
• four independent modules (a module defines a set of process data which is consistent and synchronized)
• combination of data from different slaves (validity of data is important)
• cyclic process data diagnosis for each sync unit
• if process data in one sync unit is invalid: separate reaction of control application can be defined
• for Multi-Task-Operation: each Task has own Sync-Unit/Frame (read/write process data in different task cycles)
Æ reduces bus load!
• Useful for applications with machine parts which can be out of order (planned or unplanned) and the rest of the
machine should work. ÆSync Units help to structure these applications
• granularity depends on EtherCAT Slaves
• each EtherCAT Slave defines one or more process data areas which can be exchanged synchronous and consistent
• The number of independent process data areas depends on the implementation and resources of the EtherCAT Slave
Controller (Sync Manager and FMMU channels)

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Master Settings Master Configuration Online: Scan Devices
Select EtherCAT Device
Offline: Insert EtherCAT Master Device
Select and configure network adapter

Slave Settings Slave Configuration Slaves Configuration

Startup Data
CANopen over EtherCAT, CoE
File over EtherCAT, FoE
Firmware Update (Bootstrap)

Master Diagnosis FrameStates and FrameWcStates

Device State

Only in Emergency Cases Emergency Scan Only in Config Mode available!

Checks Network and looks for Slaves
Scans the network slave by slave!
Flat List of found Slave (no topology)
Includes Link Information

Frames

• Task with I/O = one Ethernet frame = one to 15 datagrams (one Ethernet frames transports up to 1480 bytes)

- If more than 15 datagrams necessary Æ new frame with same timing

- If more than 1480 bytes Æ new frame with same timing

• Default: up to 4 tasks with own I/O

- If more than 4 frames necessary Æ all low prio I/Os in one (or more) frames with the timing of the low prio task

• Every Ethernet frame has a Frame Check Sequence (FCS)

• FCS has a 16bit CRC
• frames can be destroyed or damaged while running through the network
• EtherCAT Master sums CRC errors in master and in every slave
• CRC errors result from
- cabling errors
- contact problems
- loose contacts
- not fixed connectors

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Working Counter
Each EtherCAT Telegram ends with a 16 bit Working Counter. Each Slave Controller which successfully process the EtherCAT
command (read/write), increases the Working Counter. The Master compares the received Working Counter with the calculated
data, it allows the system to determine if the command could be successfully execute.

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Topology

Star topology with  
Real Time 

EK1122

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Redundant System

- requires optional TwinCAT software

normal setup

redundant setup

If one station is disconnected, powered down or is missing, all remaining stations will still be communicating

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2. EtherCAT Master
Adapter Card

Advanced Settings

Configuration of
Master Info Data

EtherCAT Master - Advanced Setting “Stay at PREOP until sync task is started”:
In this case EtherCAT is waiting in PREOP with the switching to OP until the triggering task is running (possibly the PLC-
Bootproject). This should be the default setting and usually helps to avoid startup problems.

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EtherCAT - Topology

EtherCAT
CAN over EtherCAT
Profibus over EtherCAT

ƒ graphically view to all slaves in right topology

ƒ all diagnostic information directly in one view
ƒ uses ADS Interface
ƒ detailled information on click
ƒ ActiveX control: can also be used in your application

Online

Tabs:
- EtherCAT
- Online
- Process Data

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EtherCAT State

System Manager: Online Slave View

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Example:
F10 Machine

Layout

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EtherCAT State Machine

EtherCAT - ADS Interface to EtherCAT Master/Slave

• Communication Interface for EtherCAT Devices

EtherCAT Master Net Id +

Port (0xFFFF for Master, Slave Address for Slave) +

Index Group +

Index Offset =

Complete Access

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Master Interface

ADS Port Meaning

65535 (0xFFFF) General Ads services handled by the master directly.

0x1 - 0xFFFE This is an ADS service directed at an individual slave device. The port
(fixed address of a slave device) number is the same as the EtherCAT address of the slave device.

Master Interface – Example

Index Group Index Offset Meaning

0x00000003 0x00000100 Returns current state of master.

0x00000006 0x00000000 Returns the number of projected slaves.

Slave Interface – CANopen over EtherCAT

Index Group Index Offset Meaning

0x0000F302 Index and Subindex of an SDO SDO Upload/Download Request.

(coded see InfoSystem!) The object is selected with the
Example: index offset.
0x1c120001:
index = 0x1c12, subindex = 1

Slave Interface – Servo Drive over EtherCAT

Index Group Index Offset Meaning

0x0000F420 IDN = LOWORD(0x0000yyyy) Upload/Download IDN

HIWORD for special attributes!
(coded see Beckhoff InfoSystem!)

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Online - Additional Debug Information

Online - Additional Debug Information

Slave State
ESC Build

Master State

Frame Statistic

Number of Cyclic Frames Number of A-Cyclic Frames

Transmit/Receive Errors in Miniport Driver

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In every cycle, synchronous with the cycle
- Working Counter
Æchecks the reading and/or writing of process data
Æreaction must be done in the application
Asynchronous, not in every cycle, event triggered
- Master State
Æ State Machine of the master
Æ Device state
- Slave State
Æ State Machine
Æ Link state

Online - Physical Address (Register 0010)

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Online - Physical Address

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Online - Physical Address

Online - AmsNetId

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Online - AmsNetId

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InfoData

CfgSlaveCount (Configured Slave Count) Actual Slave Count (read)

Every “active" slave does count: EK1100, EK1110, BK1120

EL 1xxx/2xxx/3xxx/4xxx/5xxx/6xxx/9xxx (with diagnostics; like EL9x10)
“Passive" slaves and KL’s don’t count: EL 9xxx (without diagnostics, like EL9x00)
KL’s on the BK1120!

InfoData

AMS Net ID of EtherCAT Master

“InfoData” process images are not updated in every cycle

- Update on event/change
- Mappable variables
- i.e. map NetIds instead of using them directly!

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Inputs - FrmXState (Frame X State)

Bit Meaning

0 (0x0001) 1. EtherCAT command not sent

Frame Number
1 (0x0002) 2. EtherCAT command not sent

2 (0x0004) 3. EtherCAT command not sent

…..

14 (0x4000) 15. EtherCAT command not sent

15 (0x8000) complete frame not sent

Inputs - FrmXWcState (Frame X Watchdog State)

Bit Meaning

0 (0x0001) wrong WC of 1. EtherCAT command received

1 (0x0002) wrong WC of 2. EtherCAT command received

2 (0x0004) wrong WC of 3. EtherCAT command received

14 (0x4000) wrong WC of 15. EtherCAT command received

15 (0x8000) complete frame missing

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Inputs - DevState

Bit Meaning
0 (0x0001) Link error detected.

1 (0x0002) I/O locked after link error (I/O reset required)

2 (0x0004) Link error (redundancy adapter)

3 (0x0008) Missing one frame (redundancy mode)

4 (0x0010) Out of send resources (I/O reset required)

5 (0x0020) Watchdog triggered

6 (0x0040) Ethernet driver (miniport) not found

7 (0x0080) I/O reset active

8 (0x0100) At least one device in 'INIT' state

9 (0x0200) At least one device in 'PRE-OP' state

10 (0x0400) At least one device in 'SAFE-OP' state

11 (0x0800) At least one device indicates an error state

12 (0x1000) DC not in sync (DC = distributed clocks)

Outputs - FrmXCtrl (Frame X Control)

Bit Meaning
0 (0x0001) 0x0001 = prevent 1. EtherCAT command from
sending (request NOP)

1 (0x0002) 0x0002 = prevent 2. EtherCAT command from

sending (request NOP)

2 (0x0004) 0x0004 = prevent 4. EtherCAT command from

sending (request NOP)

14 (0x4000) 0x4000 = prevent 15. EtherCAT command from

sending (request NOP)

15 (0x8000) Prevent complete frame from sending

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Output - FrmXWcCtrl (Frame X Watchdog Control)

Bit Meaning
0 (0x0001) 0x0001 = copy data with wrong working
counter of 1. EtherCAT command

1 (0x0002) 0x0002 = copy data with wrong working

counter of 2. EtherCAT command

2 (0x0004) 0x0004 = copy data with wrong working

counter of 4. EtherCAT command

14 (0x4000) 0x4000 = copy data with wrong working

counter of 15. EtherCAT command

15 (0x8000) copy data with wrong working counter

for all commands

Advanced Configuration Data

Master Identity

Configured Slaves

Slave States (below; not shown)

(Access via CoE, ADS)

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3. EtherCAT Coupler EK1100

EtherCAT settings

Fix EtherCAT address

Auto Inc Addr: The Auto Increment Address of the EtherCAT slave device. Auto-increment addressing can be used to address
each slave device via its physical position in the communication ring. Auto-increment addressing is used during the start-up phase,
during which the master assigns the EtherCAT Address to the slaves. The first slave in the ring has an address of 0 and for each
following the addresses is decremented (0xFFFF(-1), 0xFFFE(-2) etc.).
EtherCAT Addr: The fixed Address of the EtherCAT slave device. This address is set by the master during the start-up phase.
To change the default value you have to check the box left to the address.

Advanced settings

Default: Check of Vendor Id (Beckhoff: 2)

Check of Product Code (see below)
Don’t check Revision Number (example EL3142-0000-0000)
If mismatch found, VendorProductRevisionSerial error will be displayed.

Vendor ID Baumueller 0x15a (346)

Beckhoff 0x02 (2)
MTS 0x40 (64)

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InfoData - State

Bit Meaning
0x___1 Slave in 'INIT' state

0x___2 Slave in 'PREOP' state

0x___3 Slave in 'BOOT' state

0x___4 Slave in 'SAFEOP' state

0x___8 Slave in 'OP' state

0x0010 Slave signals error

0x0020 Invalid vendorId, productCode... read

0x0100 Slave not present

0x0200 Slave signals link error

0x0400 Slave signals missing link

0x0800 Slave signals unexpected link

0x1000 Communication port A

0x2000 Communication port B

0x4000 Communication port C

0x8000 Communication port D

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Online - CRC

CRC: 0 Port A
0, 0 Port A, B
0, 0, 0 Port A, B, C
0, 0, 0, 0 Port A, B, C, D

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Port Status
Carrier / Open Incoming EtherCAT frame (left) and outgoing frame (right)
No Carrier / Closed Last EtherCAT terminal (no terminal on port B, right)

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Working Counter - WC
SlaveDiagnosis WcState:
EtherCAT Training
Variable of Type BOOL
Shows Working Counter State from one EtherCAT Slave
0 (FALSE) = valid Working Counter
1 1 (TRUE) = invalid Working Counter

An invalid Working Counter State means that one EtherCAT Command for updating the Inputs and Outputs has an incorrect WC.
With this EtherCAT Command more than one Slave can be addressed. (Every Slave in this command has the same WC 1.)
Check the Slave State to see which Slave is responsible for the Working Counter error.

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EtherCAT command

EtherCAT command
Network Load

EtherCAT Working Counter

Meaning

APRD Auto Increment Physical Read

NPRD Node-Addressed Physical Read

LRD Logical Read

BRD Broadcast Read

APWR Auto Increment Physical Write

NPWR Node-Addressed Physical Write

LWR Logical Write

BWR Broadcast Write

LRW Logical Read Write

ARMW Auto Increment Physical Read Multiple Write

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Configuration example with Profibus and CAN with 3 Trigger (additional) Tasks

User Defined Sync Unit Tasks

Task to trigger Cycle Time Frame Priority

FAST EtherCAT I/O 0.25ms Frame 0 0
Profibus Profibus I/O 2ms Frame 1 1

CAN CAN I/O 10ms Frame 2 2

CAN

Profibus

EtherCAT

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4. EtherCAT Terminals
Startup Parameter list; example for EL3142

Offset and Gain (Accessible from the PLC)

WcState (Watchdog State)

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InfoData - State (see EK1100 State)

If EL9011 is used, the terminal before will always report

State = 0x0008, whether the EL9011 is plugged in or not.
If EL9010 is used, the terminal before will report State =
0x0008 when EL9010 is plugged in and State = 0x2408
when EL9010 is not plugged in!
(On the EL9010 6 gold contacts PIN 3 and 5 resp. 4 and 6 are
internally connected.)

InfoData - AdsAddr (ADS Address)

Configuration of
Slave Info Data

CoE–Online - Parameter Settings

(Variables are accessible from the PLC)

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Other fieldbusses

Example

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Profibus Master Terminal EL6731

EL6731 Profibus Master Process Data

Startup Parameter

CoE EtherCAT Online Profibus settings (See FC310x Documentation)

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Profibus Master EL6731 (Terminal 16) on EtherCAT EK1100

Profibus Slaves on Profibus Master EL6731

(Term 16 on EtherCAT)

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CAN Master Terminal EL6751

EtherCAT Process Data and CAN settings below (See FC510x Documentation)

Software Version

CANopen Setup (See FC510x Documentation) Online Status of CANopen Process Data

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5. TwinCAT PLC

PLC Functionblocks for EtherCAT Master/Slave

• Uses ADS Interfaces

• Same Look-and-Feel for all Functionblocks

PLC Functionblocks – Overview

Name Meaning

FB_EcCoeSdoRead SDO(Service Data Object)-Access

Read data from an EtherCAT Slave object directory (Mailbox communication necessary!)

FB_EcCoeSdoWrite SDO-Download
Write to EtherCAT Slave object directory

Name Meaning

FB_EcSoeRead Read Parameter via "Servo Drive Profile over EtherCAT“ (SoE) (Mailbox communication
necessary!)

FB_EcSoeWrite Write Parameter via "Servo Drive Profile over EtherCAT“ (SoE)

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Name Meaning

FB_EcGetAllCrcErrors Read CRC-Error Counter from all Slaves

FB_EcGetAllSlaveAddr Read EtherCAT Addresses from all Slaves

FB_EcGetAllSlaveStates Read State and Link State from all Slaves

Name Meaning

FB_EcGetMasterState Get State from Master

FB_EcGetSlaveCount Get Number of Slaves from Master

FB_EcGetSlaveCrcError Get CRC-Error Counter from one single Slave (for all single Ports A, B, C)

FB_EcGetSlaveIdentity Get CANopen Identity from one single Slave

FB_EcGetSlaveState Get EtherCAT State and Link State from one single Slave

FB_EcReqSlaveState Request a new EtherCAT State for one single Slave

FB_EcGetConfSlave Get list of all configured EtherCAT Slaves

FB_EcGetScannedSlaves Get list of all scanned (real existing) EtherCAT Slaves

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Name Meaning

FB_EcFoeOpen Opens a FileOverEtherCAT (FoE) connection

FB_EcFoeAccess Gives access to FoE connection

FB_EcFoeClose Closes a FoE connection

FB_EcFoeLoad Loads a file over a FoE connection

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PLC Functionblocks – Example

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6. EtherCAT Diagnosis
ƒ General Overview
ƒ Diagnosis with TwinCAT System Manager
ƒ Diagnosis with TwinCAT Topology View (see page 8)
ƒ Diagnosis with PLC Library
ƒ Troubleshooting
ƒ Advanced Diagnosis with Network Monitor

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Diagnosis with TwinCAT System Manager

E-Bus Current

EL9400 will not be scanned and therefore not shown. The E-Bus power will not be shown correct:

To resolve the problem (after a scan), the EL94x0 must be added to the configuration manually:

(Note: EK1100-0000-999x: 500mA

EK1100-0000-0000: 2000mA)

EL9110 vs. EL9100 and EL9410 vs. EL9400

Bus End Terminal 3459042 EL9010

Bus End Cap 4142093 EL9011
Potential Terminal 24V, 10A 3459041 EL9100
Potential Terminal 24V, 10A, with diagnostics 5276140 EL9110 active
Power Supply Terminal for E-Bus, 2A 3459043 EL9400
Power Supply Terminal for E-Bus, 2A, with diagnostics 5276145 EL9410 active

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ESC Build - FPGA/ASIC

Master Diagnosis – Process Images

Process Images
(Note: The number of images depends
on the number of tasks/frames.)

Process Image Info

Diagnostics Info

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Emergency Scan (Quality)
(in Configuration Mode only)

- Only in Config Mode available!

- Checks Network and looks for Slaves
ƒ Scans the network slave by slave!
ƒ Flat List of found Slave (no topology)
ƒ frame statistic (tests with 10,1000 and more frames)
ƒ Includes Link Information

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With Communication Error

Without Communication Error

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Simulated Failure
EL3102 removed from Terminal Stack (EtherCAT and TwinCAT are running)

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Port Status EL3102 (Current State: INIT, Requested: OP)

Port Status EK1100 (one before EL3102) – Port B (EL3102) = “No Carrier / Closed”

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Compare Projects / EtherCAT configurations
Scan Devices (F5)
- shows differences in red
- disable/ignore/delete functionality
- copy function to match configurations

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Procedure to locate and eliminate EtherCAT problems via System Manager

1. Check Slave States to find topology problems

2. Check for the priorities and cycle times of the tasks in the tsm (priority inversion?)

3. Check for cycle time exceeds of the triggering tasks

Æ leads to jitter on EtherCAT

4. Check for busy counts of synchronous mappings

Æ leads to jitter on EtherCAT

5. Check if I/O at task begin or at the end of the task?

Æ I/O at the end of a PLC task leads to jitter on EtherCAT due to changing execution times

6. Check for lost frames and TX/RX errors

Æ critical during startup

RX errors may count up faster than lost frames, if a frame is split into multiple pieces
Last row shows RX and TX errors of the NIC, there is no distinguishing between cyclic/queued frames
Queued frames are non cyclic (for diagnostic, CoE, SoE, EoE, AoE, …) from PLC, System Manager, Applications

7. Check for CRCs

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On the way from the master through the terminal

Æ search for the first slave starting at the master with a CRC on port A
Æ slave 4 (with slave address 1004) is detecting the real fault
Æ the faults on port B of Slave 2 (port address 1002) are green faults due older to FPGA terminals,
Æ ASIC terminals show red faults (the ASIC terminal determines if the detected CRC is already reported)
Æ the revision of the slave (>= ELxxxx-xxxx-0016 is usually an ASIC terminal)
Æ the ESC build <> 0 show usually an FPGA
Æ problem is located between/at slave 3 and/or slave 4

On the way back to the master

Æ search for the first slave starting at the last slave in the topology with a CRC on port B-D
Æ here slave 3 (with slave address 1003) is detecting the real fault
Æ the faults on port B of Slave 2 (port address 1002) are green faults due older to FPGA terminals,
Æ ASIC terminals show red faults (the ASIC terminal determines if the detected CRC is already reported)
Æ the revision of the slave (>= ELxxxx-xxxx-0016 is usually an ASIC terminal)
Æ the ESC build <> 0 show usually an FPGA
Æ problem is located between/at slave 3 and/or slave 4

Mixed

Æ see both other cases above

Æ problem is located between/at slave 3 and/or slave 4
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8. Check for old ESC builds (0x0000 = ASIC, 0x0001 … 0x000C = FPGA) if CRCs are happening

9. Evaluate CRCs
Æ distinguish between red and green errors
(only ASIC terminals point only to the first error location, FPGA terminals reflect the same error again)

CRC in first column (port A) is on the way to collect/distribute data

Æ first CRC error from the master is pointing to the problem

CRC in other column (port B-D) are on the way back to the master
Æ first CRC error from the end of the list is pointing to the problem

CRCs of cyclic frames lead to lost frames

10. Watch the machine cycle if CRCs always happen with a certain motion. This might be different in Automatic
Mode/Semi Automatic Mode.

E.g. a conveyor starts when the CRCs are generated. Or a mold is opened/closed when the CRCs are generated.

11. Check for current consumption

12. Check for the DevState of the EtherCAT master, if it indicates a problem

13. Check for the FrmxWcState or the WcState of a terminal

14. Check for multiple passive terminals (like EL9100, EL9400) or for passive terminals beside terminals in a double
width (KM-) housing (like EL67xx, EK1122, …)

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15. Make emergency scans in config mode for a few times with 100 frames per slave in order to find weak connections

16. Check for common or isolated 24V power supply to Us and Up

Æ isolate the power supply for E-Bus and outputs

17. Check for common or isolated 24V power supply to E-Bus and drives
Æ isolate the power supply for E-Bus from the 24V power for drives

18. Check for proper shielding of EtherCAT cables and of signal cables

19. Check for proper PE wiring to the EK1100

20. Check for pulling force on the wires to a terminal, the terminal might get pulled away from the DIN rail

21. Check that all terminals are attached to the DIN rail and that the couplers are locked to it

22. Replace passive terminals with active terminals (like EL9400 with EL9410)

23. Isolate erroneous terminal by adding active terminals (like EL1004) around the problem terminal

24. Isolate the terminal by shifting it to an own EK1100 coupler

25. Isolate the faulty terminal to its own sync unit in order to split the influence from other terminals to the WcState
of this terminal

26. Use external shielded EtherCAT cables

27. Check the DC-Diagnose online if DC is used in order to evaluate the quality of the distributed clocks
(ratio early/late, max. deviation)

28. Use the TwinCAT Scope to scope cyclic diagnostic data

29. Finally use the ET2000 in combination with Wireshark in order to find problems on the EtherCAT wire

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List of probable causes for CRCs and lost frames due to noise on E-Bus or EtherCAT
‐ 24V power supply is the same for E-Bus and drives
‐ 24V power supply is patched from Output Voltage to electronic voltage on a coupler (Up and Us)
‐ Unshielded/wrong shielded drive power cables
‐ Improper use of drives in an unsupported mode (i.e. without an N)

‐ Unshielded actor cables

‐ Combined cables for EtherCAT or sensors in combination with drive power cables
‐ Unshielded EtherCAT cables
‐ Pinched EtherCAT cables
‐ Self crimped (and untested) EtherCAT cables (if the crimping tool does not fit completely to the connectors)
‐ Multiple time extended EtherCAT cable between two slaves (using multiple cable connectors)
‐ Very long cables (close to 100m)

‐ Ground loops
‐ 24V power supply is actually less then 20V
‐ Overload of the E-Bus power supply (too few EL94x0)

‐ Loose terminals on the DIN rail due to pulling force on the attached wires or due to not locked couplers
‐ Too many passive terminals in a row in combination with the noise issues
‐ Passive terminals beside double sized terminals (KM-housing) like EL67xx, EK1122, …

‐ Third party transformation of EtherCAT via opto couplers from copper to optical wire
‐ Slip rings

List of probable causes for startup problems with EtherCAT

‐ Usage of third party EtherCAT components with a faulty or incomplete EtherCAT slave implementation
‐ Too many CRCs or lost frames on TwinCAT startup
‐ Too many cycle time exceeds on TwinCAT
‐ DC shift times are wrongly setup (large deviation on the DC diagnostic of the master)
Æ shift times are calculated too small,
Æ fieldbus gateway (Profibus MC) is overloaded or getting massive repeats due to noise
‐ Wrong mixture of task priorities and cycle times of PLC/NC/additional tasks
‐ Extremely jittering execution time of multiple PLC task
‐ Hot connect and cable redundancy in very old TwinCAT versions (late 2.11/2.11 R2 is suggested)
‐ Not waiting in PREOP at the Master for the triggering tasks to be started

Diagnostic from within the PLC

‐ Evaluate the Master DevState cyclically
‐ Evaluate the FrameXWcState cyclically
‐ Evaluate the slave count cyclically

In case of a diagnostic change indicated via cyclic diagnostic execute some acyclic diagnostic
‐ Read and evaluated the frame statistic
‐ Read and evaluated the CRCs on the various ports
‐ Read and evaluated the EtherCAT slave states/link state
‐ Read and evaluated the slave identification
‐ …

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Supporting older FPGA cards with new TwinCAT Versions / Builds

If an older FPGA version EL card is used with newer version of TwinCAT, it can happen that this card goes in ERR INIT
mode because TwinCAT may recognize this card as a new ASIC version while it physically is an older FPGA version.
Not all the old revision numbers (XML) will be shown by default in the System Manager when adding a new card:

In order to see all new and older revision numbers, select the 2 check boxes below and then select the correct type:

Updating Device Description (XML)

TwinCAT System Manager allows updating all the EtherCAT card device description (XML) online. An internet connection
is required for the upload. Go to Options -> Update EtherCAT Device Description -> select Beckhoff Automation GmbH:

After the update is done, it will show how many files have been updates in the folder C:\TwinCAT\IO\EtherCAT\

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Diagnosis with TwinCAT PLC Library

FrmxWcState

Diagnosis – Step by Step

• Check FrmXWcState for all Frames (X = 1..n)
• Check Master State
• If FrmXWcState for Frame X <> 0 then
• detailed examination necessary
• Check Slave State for all Slave
• reason:
• Slave Error
• check Slave
• Link Error
• check cables

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Get EtherCAT Master State

Master Problem?
• wrong State?
• Link Error?
• min. one Slave with wrong State?

Get EtherCAT Slave States

Working Counter Problem?

• What was the reason for this problem?
• Check States of all Slaves!

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One Structure for each single Slave with
• Device State
• Link State

Number of Slaves

Iteration over all Slaves; Example: to get the Identity of every Slave

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Get Identity from a Slave

EL3142-0000-0000

TwinCAT InfoSys:

Minimal EtherCAT Diagnostic’s example

http://infosys.beckhoff.com/content/1033/tcplclibethercat/html/tcplclibtcethercat_overview.htm?id=12757

Minimal EtherCAT PLC Drive Diagnostics example

http://infosys.beckhoff.com/content/1033/tcplclibdrive/html/tcplclibdrive_intro.htm?id=12854

Minimal EtherCAT MC2 Drive Diagnostics example

http://infosys.beckhoff.com/content/1033/tcplclibmc2_drive/html/tcplclibmc2_drive_intro.htm?id=13382

Minimal EtherCAT NC Drive Diagnostics example

http://infosys.beckhoff.com/content/1033/tcplclibncdrive/html/tcplclibncdrive_intro.htm?id=13451

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 EtherCAT Training
Troubleshooting
EK1100

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All EtherCAT devices with a connector (e.g. RJ45, M12), must have a Link/Activity display. Devices without connector
could have such a display.

– Status (as with standard Ethernet components)

• LED out: no connection
• LED on: connection
• LED blinking: communication

The RUN LED indicates the status of the EtherCAT device -> see State Machine

– Status:
• off: INIT
• blinking Pre-OP - Pre-Operational
• single flash Safe-OP - Safe-Operational
• on OP - Operational
• flickering Bootstrap

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EK1110

EL3314

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Advanced Diagnosis with Network Monitor

Master Diagnosis (Experts only!)

ƒ Diagnosis with Wireshark, Ethereal or Network Monitor

EtherCAT Diagnosis with Wireshark/Ethereal

EtherCAT frames are Ethernet frames, so Standard Ethernet Protocol debugger can be used!
Æ Microsoft Network Monitor
Æ WireShark/Ethereal www.wireshark.org
For both Network Monitors a parser for EtherCAT is available www.ethercat.org

Ethereal installation:
1) execute the setup file for Ethereal/Wireshark
2) includes: installation for WinPcap
3) Not necessary any more:
4) copy the EtherCAT.dll in the Ethereal Plugins (C:\Programme\Ethereal\plugins\0.10.11)
5) Activate the Promiscuous Mode on the EtherCAT Adapter
6)

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Standard Switch shows only PC times, no Distributed Clocks

Æ ET 2000 supports Distributed Clocks
Æ Resolution: nano seconds!
Æ synchronized recording of up to four independent channels
Æ high timestamp resolution of 1 ns
Æ connected to any GBit Ethernet port (uplink)
Æ open WinPcap software interface
Æ used with freely available network monitors such as Wireshark

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Wireshark Online

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7. HPN List
EtherCAT Bus Coupler (E-Bus) 3459050 EK1100
EtherCAT Extension 4731349 EK1110
EtherCAT 2 Port Junction 4731326 EK1122
EtherCAT Bus Coupler (K-Bus) 3459051 BK1120
Digital in 24V, 4 channel, 3.0ms 3905764 EL1004
Digital in 24V, 4 channel, 10µs; 2 wire 3454441 EL1014
Digital in 24V, 4 channel, 10µs; 2 or 3 wire 4808165 EL1114
Digital in 24V, 2 channel XFC 4677708 EL1262
Digital out 24V, 4 channel, 0.5A 3459021 EL2004
Digital out 24V, 8 channel, 0.5A 3905733 EL2008
Digital out 24V, 4 channel, 2.0A 3905765 EL2024
Digital out 24V, 2 channel, 2.0A 3459025 EL2032
Digital out 24V, 0.5A 2 channel XFC 4677718 EL2262
2 Channel Digital output relay EL2622 2A/5A 4443659 EL2622
Analog in 0V...+10V, 2 channel, differential, 12bit 4443654 EL3062
Analog in 0V...+10V, 4 channel, differential, 12bit 4443653 EL3064
Analog in -10V...+10V, 2 channel, differential, 16bit 3459026 EL3102
Analog in 4…20mA, 2 channel, single-ended, 16bit 3459030 EL3152
Analog Input PT100 (RTD) for 2-, 3- or 4-wire connection 4443661 EL3202
Thermocouple in (2 channel) (K-type default) 4443660 EL3312
Thermocouple in (4 channel) (K-type default) 3905766 EL3314
3-phase power measurement terminal, max. 500V AC 3~ 5053979 EL3403-0010
Analog Input +/-10V 2-ch XFC 4903401 EL3702
Analog in, 0-20mA 2 channel XFC 4677689 EL3742
Analog out 0…10V, 2 channel, single-ended, 16bit 3459033 EL4102
Analog out -10V…10V, 2 channel, single-ended, 16bit 3459036 EL4132
Analog out, +/-10V 2 channel XFC 4677724 EL4732
Serial RS232 on EtherCAT 4443663 EL6001
Serial RS422/485 on EtherCAT 4443664 EL6021
Serial RS422/485 on EtherCAT, 2 x D Sub 4964762 EL6022
Ethernet over EtherCAT, 1 channel 4563714 EL6601
Ethernet over EtherCAT, 4 channel switch card 4964748 EL6614
ProfiNET IRT over EtherCAT 4563718 EL6632
Profibus over EtherCAT, Master Terminal 3459048 EL6731
CANopen over EtherCAT, Slave Terminal 4254504 EL6751-0010
Bus End Terminal 3459042 EL9010
Bus End Cap 4142093 EL9011
Potential Terminal 24V, 10A 3459041 EL9100
Potential Terminal 24V, 10A, with diagnostics 5276140 EL9110
Potential Distribution Terminal, 8 channel 4142096 EL9187
Power Supply Terminal for E-Bus, 2A 3459043 EL9400
Power Supply Terminal for E-Bus, 2A, with diagnostics 5276145 EL9410
EL6731-0000 Profibus Master Leap
EL6732-0000 ProfiNET IRT Master F10, Siemens ProfiNET Sinamics Drives
EL6751-0010 CANopen Slave Wittmann Robot
EL6021 RS485 Altanium Controller
EL6601 Ethernet TCP/IP CBW Robot

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8. Notes
Update Firmware (Experts only!)

1. switch TwinCAT to RUN mode

2. go to ELxxxx card in the SystemManager, “Online” tab and switch mode to “Bootstrap” state
3. select “Download” button, select the firmware file “xxxx.efw”
4. select “Open” button
5. after the update has been completed, switch back in “INIT” state first
6. once in “INIT” state, switch to “OP” state

Note: The firmware is saved with the I/O card. In case of a replacement, the firmware might have to be loaded again to the
replacement card. Verify first the version loaded on this card; it might be up-to-date or even newer.

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